manufacturing plant for production of solvents, dyes, paint primers and finishing paints ·...
TRANSCRIPT
Manufacturing Plant for Production of Solvents,
Dyes, Paint Primers and Finishing Paints
with control, manufacturing, formulation
and automatic dosage system
NTD builds turn-key installations for production od special products. We installed from storage parks and
circulation systems of liquid row material, to the unloading and circulation of powders, additives dosage,
dispersion equipment, manufacturing tanks, packaging systems, etc.
As a sample, this plant includes:
§ 3 manufacturing plants management is included in the control system.
§ Main Manufacturing System: Dissolver on 4 tanks with load cells (weight).
§ Other manufacturing systems: on embedded scales and fixed agitator.
§ Additives dosage and mills for micro-elements included, etc.
Nuevas Técnicas de Dispersión, S.L.
NTD
Operario Activo
Pol. Ind. La Esperanza, C/Comunidad de Murcia, 15212400 Segorbe (Castellón) EspañaTel. +34 964714032 - [email protected]
Control System of Processes and Productionat Industrial Plants
General Screen
Control system supplied by NTD is a data base developed in Windows environment with thefollowing features:
This system eases an absolute control over the processes, not only operational, but also overproduction.
Link with other management systems (AS-400, BAAN, SAP, etc.) is also possible.
Easy use. Only basic knowlodge of computers is required to work with the program.
§ General screen. It shows a diagram of all different processes of the plant. It gives a dynamic view of all control devices.§ Possibility of action over components (motors, pumps, valves, etc.)§ Setting of masters: products, lines, workers, etc.§ Starting and monitoring processes (M.O.)§ Alarm management and setting.§ User management (workers).§ Reporting: formulas, consumption of products, alarms, etc.
Operario activo
SUPERVISION AND CONTROL SYSTEMON PRODUCTION OF SOLVENTS, DYES,
PAINT PRIMERS AND FINISHING PAINTS
INDEX
Supervisión and control system ...............................................................................4 - 6
Pumps - Motors.........................................................................................................6 - 7
Menu...............................................................................................................................8
Components....................................................................................................................9
Workers.........................................................................................................................10
General operations / orders...........................................................................................11
Formulas................................................................................................................12 - 15
Hours of Operation................................................................................................15 - 16
Alarm indicator......................................................................................................16 - 18
Alarm report..........................................................................................................18 - 19
Automatic production report.................................................................................19 - 21
Manual production report......................................................................................21 - 23
Way of operation...................................................................................................24 - 28
Formulation...........................................................................................................29 - 35
Page
Nuevas Técnicas de Dispersión, S.L.
NTDPol. Ind. La Esperanza, C/ Comunidad de Murcia, 15212400 Segorbe (Castellón) EspañaTel. +34 964714032 - [email protected]
SUPERVISION AND CONTROL SYSTEM
MANUAL OF OPERATION
Screenplays containing options that are described in following pages, constitutes
integrated Control and Supervision Program.
The Program is developed in Windows environment; therefore, the appropriate
icon must be clicked on desktop to execute the program.
Name of icon in this guide is “Gralsa”.
Mouse double click on the icon executes the program, coming out the general
screen. This is the centre of operations and the access to detailed screens and Menu
options, which links with the operations.
Depending on computers you are working with, you will get general diagram of
the appropriate manufacturing plant: 1, 2 or 3.
GENERAL SCREENS
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5
As you can see on pictures below, there is a general view of all components of
installation. State of control elements are classified with different colours:
Pumps, motors
- Green: In process
- Grey: Stop
- Red: Thermal difference
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Valves:
- Verde: opened
- Black: closed
- Red: Irregularity: after request to open, the valve remains closed
Besides, when product is circulating (valve opened and pump in operation) the
line is coloured.
In addition, a legend indicates pumps operation mode:
A: Automatic (orders from computer)
L: Local (orders from electrical panel)
Choose the way of operation by means of a selector placed in electrical panel.
Apart from showing state of different components, on the upper side of each
general screen, there is a general menu, which gives access to different options of the
program.
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MENU
The program has three access levels with their respective passwords. Number 3
means maximum priority and 1 minimum priority.
Set up the access level on menu option “Security Level Setting”.
According to the configuration, you have access to some of the functions after
clicking on enable options and enter the appropriate password.
Masters Masters are described below.
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Components
Set up products used in the processes in this master.
Data fields are:
- Component code
- Component description
- % weight variation. This data is the margin of error allowed in dosages. If a
value exceed this range, dosage is interrupted.
- Tare. It refers to tare of container, that is, sacks, barrels, cans...
- Capacity of container where the product is packed.
- Bar code. This is the identification code of the product.
- Registration date. This field is fill automatically
Action buttons in all masters have the same meaning:
New. Create new register
Edit. Allow to modify registered data
Delete. Eliminate a register
Save. Record new data
Cancel. Modifications are not saved.
Print. Print data from master.
Exit. Close the window and return to general screen.
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Workers Set Workers in this master assigning them Code, Name, Security Level and
Password.
Lines Assign products to automatic lines.
In this master, you can also enter inertia data in kg. Used to close the valve in
order to compensate pipe inertia. Inertia is also set for each receiving scale.
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Time orders
Set in this masters waiting times for solvents and resins (enter time in seconds)
to take scale real time on dosages.
Orders
Click on this menu option to open manufacturing orders tab. You can create or
assign new orders.
Click new order to add a new
line, then write manufacturing
plant, No. of manufacturing
order, formula and amount.
There is an empty field to add
Comments. On the right end of
the line, another field indicates
state of MO: stopped, pendent,
finished.
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Formulas
You can set up formulas for different manufacturing processes.
You can use buttons on the bottom of screen to make actions over a formula:
New: Click New to create a formula. To fill empty fields of new formula, first,
go to Code button to enter a new code and then name the formula in Description. After
that, go to Sequence field (Sec), which is the first field of detailed data.
Detailed data consist of the following fields:
Sequence No: Better, enter from 10 to 10 to enable the addition of steps between
sequences.
Process code-Description code
Go to Process code and press Enter.
An info window appears with a list of all possible actions. To select one option,
go to the option wanted and press Enter. If you do not know the option, write the code
and press Enter.
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The meaning of these actions is described bellow:
ADD AUTOMATIC – Perform automatic dosage. Program acts over pumps and
valves to dose the product through the lines
RESINS COLLECTOR CLEANING – Set this action when you want to perform
an automatic unloading of solvent going through resin collector.
ADD MANUAL – This action puts all manual dosages together.
AGITATE – Set this action for agitation processes.
CIRCULATION, SUPERMILL CIRCULATION, GRINDOMIX, FILTRATION –
Set these actions to circulate the product between deposits and machines.
Once the action has been set up Enter the following data:
Product Code. Go to this field, write the code to validate and press enter. If you
do not know the code, press Enter to open a dropdown list with all possible products. To
select one option, go to the option desired with scroll button or scroll arrow and press
Enter.
If user clicks on the option or press another key, a help window comes out with
all components. Go to the one wanted and press Enter to select.
Batch. Enter product batch number.
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Source tank. Set source tank for circulation actions. Leave it empty in other
processes.
The code assigned is variable and generic. Set this code when entering
manufacturing formula. There are generic codes already defined from C1 to C40. Use
always one of these.
Receiving tank. Enter generic code for the deposit where you are performing this
manufacturing step. Fill this data in every step of formula. Likewise, generic code will
be defined in the formula and in tanks and weighing processes during manufacturing
process.
For example, if you want to dose product and weight in different scales, you
must assign a theoretical tank for all of them. Likewise, if you want to weight solid
product, which are packed on sack or containers, you must assign a theoretical tank to
weight them in a particular scale.
Type. Use this memo field to write comments in formula steps. E.g.: 500 kg
tank. Verify product, etc.
Kilos. Enter amount of product to be dosed in kg.
% kg. Kg percentage of product to be dosed.
Formulas are usually edited in % and the system itself calculates the amount in
kg. However, there is a blank field to enter the formula in kg. Click on conversion
button to give values in kg and in %.
You can edit a formula both ways, but both fields (Kg and %kg) must be finally
filled. If formula is edited in kilos “1” must be written in % kg field and when the
formula is edited in % kg, “1” must be written “kg” field. When all formula data are
entered, single click on Convert Kg into % make the calculation automatically.
Speed of agitation. Enter speed of agitation in rpm. The range available is from 0
to 1500.
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Minutes of agitation. Set time of agitation in minutes. To keep agitator working
without stop, write “0”. If after that you want to stop the process in a particular step, add
a new time of agitation action with value “1”.
Other buttons perform the following actions:
Edit. Modify an existing formula
Delete. Delete the formula. Before, a dialogue box asks confirmation.
Add line. Add a new line when editing.
Delete line. Delete the line the cursor is located.
Save. Record formula or modification.
Cancel. Cancel modifications before saving.
Print. Print formula or show formula on screen.
Convert Kg into %. Convert amount in kg into values in %. Click always on this
option before saving the formula.
Save as. This helpful option allows the edition of a new formula using an old
one (which will avoid us rewrite all the fields). Simply click on this option. A window
pops up asking the code of the new formula. Click OK. Select the formula and change
data required.
Hours of operation
Click on this menu option to enter in a new window, data of hours of operation
and control elements (pumps and motor). You can reset separately each element. This is
a helpful option in maintenance of components.
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Worker Login / Logout
Click on this option to enter the worker code that works on the process. This
data is important as data processed is assigned to one worker.
Besides, actions cannot be executed without assigned worker.
Alarm indicator
Alarms
When an alarm goes off during the process, a window comes out (alarm
indicator). It shows in red, date/time of the alarm.
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When alarm is registered and is still active you will get a green indication. If the
alarm is no longer active and nobody has registered it, the indication is yellow.
Likewise, if an alarm is registered and after that, it loses the “alarm condition”,
the alarm is deleted automatically from the window and registered in Alarm history.
Double click on alarm to register it.
Click on that button to register all alarms. You will be prompted with a
dialogue box to confirm the action:
There are two more buttons:
Click on this option to add comments about alarms. Single click on alarm
wanted opens a window with a blank field to write comments.
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Click here to print the alarm report.
General Screens
Click on this option to visualized general screens of the manufacturing plants
and resin tanks.
However, you can see other manufacturing plants but you can only work on one.
Reports
This option gives access to all processed and stored data. Data is stored in
different reports that are described below:
Alarm report
Order the report within dates.
Data included in the report are alarm occurred, date/time of start, End date/time,
date/time of registration, duration and worker.
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Automatic production Report
Automatic production report is ordered between dates or by manufacturing
order. The report can summarized or detailed. To get all reports, leave fields empty.
If you want specific report, fill data field required.
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Summarized
The screen shows the report and can be also printed.
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Detailed
This report details all formulation steps and indicates start D/T, end D/T, and
planed and real amount of product.
Manual production report
Order the report within dates.
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Consumption report
This report details product consumption data. Range of data is selected between
dates, which are entered in the appropriate fields. You can request consumption of only
one product or consumption of all of them leaving the field empty (blank).
The resulting report is below:
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Exit
Click Exit to leave the application. Before, a dialogue box pops up to ask
confirmation.
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WAY OF OPERATION
The system has been developed to execute control actions individually (dosage,
agitation, etc) or linked with execution sequences, according to settled formulas.
To make any action, always assign a worker, otherwise options cannot be
selected.
To make an action on scales or agitators, first assign a tank. In order to do that,
click on scale to open the following window:
Click “Unload deposit” and enter No. of tank in the appropriate field. Then write
the name wanted on “Description” field. After that, accept and close the window. Now,
a picture of a tank is included on the scale. Click on tank to open window again. This
time the scale has the tank assigned.
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To apply a dose to a deposit, click on it to open a drop-down display and select
an action.
This model contains three actions:
ADD AUTOMATIC
RESINS COLLECTOR CLEANING
ADD MANUAL
Another display comes out when selecting add automatic. Select in the display
the solvent or resin line, which will apply the dose.
Then, another window drops down to set the quantity of product and product
data (component, batch inertia). In addition, it indicates the state of action: finished, in
process, interrupted. Some buttons are available to make other actions: Continue cycle,
Stop cycle and End action.
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After entering quantity of product in kg, and clicking Start, the system starts the
dosage. First, the appropriate valve is opened and the pump starts working. Now, state
of action field indicates “in process”. If system does not respond after clicking Start, the
program indicates the fault with an alarm message.
For example:
-Fault on valve Vd1. It means the system has opened the valve but limit switch
device does not register the action.
-Fault on pump differential. Energy on pump is cut off.
-Lack of start conditions in scale 1; possibly due to miscommunication between
scale and system.
Action in process can be interrupted clicking on “stop cycle”. Dosage applied is
memorized, so when dosing starts again it completes the programmed dose. When
dosage is completed state of action indicates Finished.
If an alarms goes off while dosage components are involve in the process (pump
differential, valve default or scale default), it is interrupted and accordingly, state of
action field will indicate Interrupted. Click Continue cycle when the problem is solved.
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Apart from automatic dosage, more actions can be executed.
Resin collector cleaning: Action linked with unloading solvent automatically
going through resins collector.
Add manual action is suitable to control manual dosages application – those
made by the worker.
Window below pops up for execution of “add manual” order:
Data to enter are kg, container tare (if it has) and product.
To make a correct action, fill the fields and click Start. As the action is done
manually, the program cannot stop the process automatically, so the worker must stop it
clicking End action. After that, the program reads the real amount of dosed product.
You must assign a tank when working with scales, both automatically and
manually.
Agitation can be also performed. To make an action on wall agitators a tank
must be also assign in this area.
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If you want to move a tank from scale 1 (where the mixture has been prepared),
click on the tank and select Remove deposit. Then, select an agitator, e.g. A1 at
destination area. This way system knows the deposit is in agitator 1. Click on deposit to
set the agitation.
Enter agitation order in rpm and time of agitation in minutes. To keep the
agitator working without stopping, write “0” on Min Time field.
Stop cycle, continue cycle and End action have the same meaning than in
previous actions.
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FORMULATION
Follow the process described below in order to make formulas automatically:
First, set manufacturing orders clicking on appropriate button on main menu. To
execute the orders click on Option Menu FORMULATION to open the following tab:
This window shows detailed information about process and also, many actions
can be executed.
When no formula is registered, formulation window appears empty. Therefore,
the first action is Enter M.O. clicking on the appropriate button.
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Indicate Batch No and click Accept. The tab is filled with formula data;
sequence, amount, rpm, time, etc.
On the upper side of the tab, there are other fields: MO, batch, planned amount,
formula, comments, worker, and state.
State field shows state of formula:
Stopped. Formula is stopped.
In process. Executing
Freeze. Interrupt a MO and enter another. This is used for floor scales.
Blocked. The formula is blocked by failure in dosage.
Apart from Enter MO there are other buttons:
Freeze OF. For floor agitators. You can stop or interrupt a MO to start another
action. Then continue the previous action. NOTE: To interrupt a MO, it must be set on
stop state and the step must be finished.
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Thaw MO. Click on this button to access to frozen MO. Click on Restore to
activate MO again.
Some tolerances are settled in dosage processes. This way when dosage exceeds
one of the tolerances, an alarm goes off and the formula is blocked. Line involved in
MO is coloured in red and “blocked” sign appears next to it. Click on Unblock to
unblock the formula. A display pops up to enter the password (user set the password on
maximum level) to unblock the formula. Formula will be stopped; therefore, start the
appropriate step.
Enter MO and click Start Step to execute it.
As a tank was assign when setting the formula, now you must indicate the
system which scale will be used.
This window only shows scales which were previously assign to a tank.
After setting the first step, system opens appropriate valves and pumps start the
application of dosages ordered.
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Consecutive automatic dosage steps will proceed automatically. However, the
worker will start manual dosage steps, circulation and agitation.
For those manual steps, operational way will be as follow:
ADD MANUAL. Click Start and assign a scale in the pop-up window.
(Previously, you must enter a tank, as it is described in pages above).
Another window pops up to select the product. This can be made with bar reader
or typing the code. If code is not correct, system do not continue.
However, the code can be force but password is required.
The correct time to put the product into the tank is when action is in process.
Scales start registering variation on weight. When dosage is finished, click End step.
Then real dosage is registered in the system.
CIRCULATE. Click Start step to start circulation process. Enter source and destination
in the pop-up window.
AGITATION. To agitate the product, place the tank under the appropriate agitator and
indicate the action to the system.
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For that purpose, click on the correct area to open “area / deposit” window
Single click on Remove Tank shows areas to place the deposit. Select the
agitator to make the agitation.
Formulation window indicates the state of steps.
Pending. Not executed yet
In process. Executing
Interrupted. The step is interrupted
Finished. The step is already done
Likewise, at the lower side of the tab there are different buttons for different
actions:
Start step: Start the execution of a step
End step. Finish a step in process.
Continue cycle. Continue the formula after the interruption (voluntary
interruption or because of safety conditions)
Stop cycle. Interrupt the process.
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Stop Formula. Interrupt the formula. Finish step in process and do not start the
following step.
End Formula. This option ends formula in process. Clicking this button, data
disappear from the screen and is registered in database of process history.
Restore step. Variables can be assign again to one step(tank, destination, etc)
Order Modification. To modify a step when it has not started yet (kg, rpm,
time).
Print. Print formulation tab.
If an alarm goes off when formula is in process (and then the process is
interrupted), visual alarm indicates the appropriate message and the state of execution
indicates “interrupted”. Once the problem is solved, click Continue cycle.
In addition, if you want to start a formula or execute a step and the system does
not execute any action, you will be prompted with an error message.
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Click OK on error message may open a new window indicating cancellation
performed by user.
To close control program, click EXIT from main menu. The program displays a
dialogue box to confirm the action.
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EExd 125 HP Dissolver
Detail of Dosing to Manufacturing Tanks
Detail of Solvent lines
Detail of Dosing to Manufacturing Tanks
Detail of Automatic Dosing on Scale
EExd 25 HP Dissolver
EExd Control Pannel
Horizontal Mill 25HP
Detail of Manual Dosing